GENUINE HOOLIGAN 170i Service Manual Download Page 85

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Engine / Reverse differential gear -

八

. Rear suspension

1.Remove the left and right rear suspension screws(7)

九

. Remove the engine hanger

Remove the engine hanger * 1 fixed nut

Remove the engine hanger * 1 mounting bolts

十

Separation of the engine and the frame

十一

. Remove the reverse differential gear Steps - please refer to the reverse differential gear(

Chapter

5-4)

Torque values:

REAR SUSPENSION (upper):4.7~5.5kg-m

REAR SUSPENSION (under):2.0~3.0kg-m

Torque values:
Engine hanger:4.0~5.0kg-m

Summary of Contents for HOOLIGAN 170i

Page 1: ...MANUAL This manual offers all service specialists with the technological procedures of maintenance repair and troubleshooting for the Hooligan 170i Four Stroke Cycle 168CC 2 valve electronic injectio...

Page 2: ...electrical wires in connection with the motorcycle in which there are 7 chapters and as references of users or mechanics during service Classification Item Page Information summary and preparation 1...

Page 3: ...L 276 KG LIGHT HEAD LAMP 12V 55W 35W PERFORMANCE TOP SPEED 95 km hr TAIL LAMP 13 5V 0 41W 12V 5W FUELCONSUMPTION 38 km l BREAKING LAMP 13 5V 1 89W HILL CLIMB 26 TURNING LIGHT 13 5V 1 58W 13 5V 1 45W E...

Page 4: ...FRONT INNER COVER FRONT FORK TUBE COMP LOWER COVER L R FRONT LNNER COVER LOWER BRAKE DISC FRT BRAKE SIDE REFLECTOR LEVER L R GRIP L R WIND SHIELD FR SIGNAL LAMP R L HEAD LIGHT COMP FRONT WHEEL BODY C...

Page 5: ...lower Exhauster Front Exhauster Rear Rear fork 2 0 2 5 5 0 6 0 4 5 6 0 3 5 4 5 2 0 3 0 3 5 0 2 0 8 1 2 10 11 2 0 2 5 4 7 5 5 2 4 3 0 2 0 3 0 3 1 0 1 2 5 2 8 Sparking plug Drain plug bolt engine oil D...

Page 6: ...wist or kink 9 Do not put any tool on the motorcycle particularly the battery unit to become a short circuit during maintenance 10 The battery in a motorcycle which has not been started for a long per...

Page 7: ...ed from the fuel tank shall be disconnected beforehand to prevent any spark or fire 6 The fuel pump to be tested shall not be empty or refilled by water or the service life will be curtailed On the ot...

Page 8: ...umping unit 3 Bearing puller tool 4 Clutch compression tool 5 Fixator 6 feeler gauge 7 Bearing Striking Tools 8 Cylinder pressure gauge 9 Test line group 10 Hook type wrench 11 RELEASING TOOL FLYWHEEL...

Page 9: ...1 16 spark plug gap gauge 17 EMS diagnostics dedicated 18 Hose clamp removal tool 19 Fuel injector cleaning tool 20 Oil seal removal tool small 21 Dial gauge Magnetic Base 22 Oil seal removal tool Lar...

Page 10: ...hich may affect the subsequent diagnoses or reparation Diagnosis assist 1 Make sure of no engine related trouble records 2 Make sure of any offered troubles 3 Follow the said procedure to complete ins...

Page 11: ...he start motor Yes Change applicable lubricant No Next step 5 Check the ECU circuit 2 Engine running but start up failing during start up General trouble location 1 Oil tank empty 2 Fuel pump 3 RPM se...

Page 12: ...nnect the ignition cable and connect a spark tester start the engine and check any high voltage flash blue white Yes Next step No Repair the ignition system 3 Press the engine temperature sensor conne...

Page 13: ...ature sensor connector and start the engine check if the engine successfully started Or install a series connected resistor 2500 in lieu of the engine temperature sensor at the engine temperature sens...

Page 14: ...gnition system 4 Check the spark plug in the cylinder and its model and gap conformable to specifications Yes Next step No Adjust or change the spark plug 5 Press the engine temperature sensor connect...

Page 15: ...he spark plug and its model and gap conformable to specifications Yes Next step No Adjustment or change 4 Check the air throttle and the idle air bypass for any carbon deposition Yes Cleaning No Next...

Page 16: ...ove the Idle governor and check the air throttle the isc and the idle air bypass for any carbon deposition Yes Clean relevant parts No Next step 4 Press the engine temperature sensor connector and sta...

Page 17: ...Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon deposition Yes Clean relevant parts No Next step 4 Press the engine temperature sensor connector and start the...

Page 18: ...ge the defective nozzle No Next step 4 Check the ECU circuit 10 Start up normal but idle speed too high General trouble location 1 Air throttle and idle air bypass 2 Vacuum tube 3 ISC 4 Engine tempera...

Page 19: ...in the cylinder and its model and gap conformable to specifications Yes Next step No Adjustment or replacement 4 Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon...

Page 20: ...linder and its model and gap conformable to specifications Yes Next step No Adjustment or replacement 4 Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon depositi...

Page 21: ...nnect a spark tester start the engine and check any high voltage flash blue white Yes Next step No Repair the ignition system 5 Check the spark plug in the cylinder and its model and gap conformable t...

Page 22: ...he install According to the reverse procedure as above B battery cover dismantle Hand turn the screw 13 take out the battery cover 7 install According to the reverse procedure as above Front fender St...

Page 23: ...1 open seat 2 Remove the bolts 2 take out the luggage compartment 1 install According to the reverse procedure as above dismantle 1 Remove the bolts Washer 7 8 Take out the rear rack 6 install Accord...

Page 24: ...bolts 5 take out the middle cover 4 install According to the reverse procedure as above Body cover dismantle 1 Remove the screws 2 Figure 1 2 Remove the screws 3 Figure 2 3 Remove the signal lamp soc...

Page 25: ...paration the rear lamp 1 with the left right body cover 5 4 2 Separate left right body cover and the left right cover 2 3 install According to the reverse procedure as above Single decomposition licen...

Page 26: ...move the self tapping screws 6 8 separating left right signal lamp 5 7 3 Remove the nut washer 3 4 separated Reflectors 2 install According to the reverse procedure as above Single decomposition Refle...

Page 27: ...use box 2 Remove the screws 10 take out the Battery box 9 install According to the reverse procedure as above Single decomposition dismantle 1 Remove the screws take out the diagnose adaptor 2 2 Remov...

Page 28: ...wer 16 install According to the reverse procedure as above Cushion dismantle 1 Remove the wire clip take out the Cushion install According to the reverse procedure as above Licence plate link plate di...

Page 29: ...e 1 Remove the screws 2 3 4 take out the upper cover 1 install According to the reverse procedure as above The lower cover of handle dismantle 1 Remove the screws 3 take out the lower cover of handle...

Page 30: ...f External Components 2 speedometer speedometer cover dismantle 1 Remove the screws 5 6 take out the speedometer 1 2 Remove the screws 3 take out the speedometer cover 2 install According to the rever...

Page 31: ...rake master cylinder 6 8 screws and take out the brake master cylinder 6 8 Figure 1 2 2 Remove the bolts 4 and right haft switch fixing screws 7 take out the grip 9 haft switch 2 and front right signa...

Page 32: ...nents 2 5 Install the brake hose place the hose fixed at A install According to the reverse procedure as above front signallamp dismantle 1 Remove the screws 3 take out the fixed plate 1 install Accor...

Page 33: ...ernal Components 2 Dismantle Windshield dismantle 1 Remove the screws 2 Figure 1 2 Remove the screws 3 Figure 2 3 Remove the screws 4 5 6 7 take out the Windshield 1 Figure 3 Parts 2 U TYPE SPRING NUT...

Page 34: ...out the turn signal 2 4 install According to the reverse procedure as above Single decomposition dismantle 1 Remove the screws 5 take out the head light 4 2 Remove the screws 3 take out the headlamp...

Page 35: ...crews 13 14 take out the front fender 12 speedmeter cable clip comp 11 16 install According to the reverse procedure as above Dismantle Foor step floor lower cover dismantle 1 Remove the screws 4 5 ta...

Page 36: ...tallation or Removal of External Components 2 NOTE dismantle install Foor step floor lower cover release rear Pressed into two fixed points withdraw the Foor step floor lower cover as arrow direction...

Page 37: ...Installation or Removal of External Components 2 Dismantle Tank lower cover dismantle Remove the screws 4 7 take out the tank lower cover 3 install According to the reverse procedure as above 37...

Page 38: ...le 1 Remove the screws 2 Figure1 2 Remove the rubber plug 5 Figure2 3 Remove the screws 4 take out the step floor 2 Figure2 install According to the reverse procedure as above Note Dismantle a pull up...

Page 39: ...Installation or Removal of External Components 2 Install Single decomposition Step floor Parts2 U TYPE SPRING NUT 39...

Page 40: ...se needle nose pliers to remove the clip 7 take out the three way assy 6 4 Use Hose clamp removal tool to open clip 3 take out the oil pipe 2 install According to the reverse procedure as above Fuel P...

Page 41: ...VER dismantle 1 Remove the self tapping screws 1 2 Remove the self tapping screws 2 3 Remove the self tapping screws 7 and hex bolts 4 take out the under cover 3 4 Remove the bolts 6 take out the fron...

Page 42: ...tle 1 Remove the screws 8 2 Use the magnet burglar key remove the magnet burglar lock assy 3 2 dismantle the fuel cap cover turn counterclockwise 3 Remove the screws 1 take out the gas cap base and pu...

Page 43: ...decomposition front inner cover dismantle Step 1 Remove the bolts 6 take out the side reflectors 5 2 Remove the self tapping screws 8 separated front inner cover upper 7 and front inner cover lower 1...

Page 44: ...the reverse procedure as above 1 Remove the Phillips head screw 5 take out the Gas cap fixing plate B 4 2 Remove the Phillips head screw 3 take out the Gas cap fixing plate A 2 3 Remove the Phillips h...

Page 45: ...l of External Components 2 Removable front inner fender dismantle Step 1 Remove the front fork assembly see 6 2 2 Remove the bolts 2 take out the front inner fender 1 install According to the reverse...

Page 46: ...of the range Oil replaced 1 Remove and clean the drain plug bolt check the gasket for any defect and replace the defective gasket with a new one Screw the bolt with the engine oil evacuated 2 Remove...

Page 47: ...ssel under the drain plug bolt remove and clean the bolt 2 Install the bolt with the gear oil evacuated 3 Open the filling orifice and pour new gear oil tighten a filling orifice bolt Torque 1 2 1 8 k...

Page 48: ...00 mile in the event of filth Check Change 1 Remove 8 set screws on the air filter cover 2 Check packing for filth or damage clean packing with high pressure air gun 3 Replace the air filter with a ne...

Page 49: ...key display SELECT ADJUST result Vehicle speed ON km Click Mile mile Click Km ODO TRIP switching ON ODO Click TRIP TRIP Click ODO Reset TRIP ON TRIP Click 3 sec Reset TRIP to 0 Reset 4T oil indicator...

Page 50: ...witch cover removable 1 Remove Wind shield the set screw and remove 1 All the power is cut off the key can be pulled out at this position B 2 The power is ON engine can be started the key can not be p...

Page 51: ...nt a Seat lock lever cable b Tank cover lever cable Adjustment screws Clockwise Tighten Counterclockwise loosen 3 7 Battery installation 1 open the battery cover 2 take out the band tool set 3 install...

Page 52: ...filth or deposited carbon Specific model CR7HSA NGK or similar substitute Spark plug gap 0 6 0 7mm 3 9 12V Charging power switch 1 Function Supply 12V DC voltage the charging power 2 Restrictions on...

Page 53: ...el Adjustment camshaft sprocket position 3 Adjustment camshaft sprocket position Remove the inner chain adjuster screws of the adjusting hole Use a slotted screwdriver into the hole clockwise the adju...

Page 54: ...b Use a feeler gauge to measure inlet and exhaust valve clearance is within the specified range 0 08mm feeler IN EX can be placed in non home 0 10mm Out of range adjustment 3 Adjustment Tools Valve ad...

Page 55: ...Tighten the fixing nut NOTE The throttle the ropes free gap adjustment the handle tube to the left Then turn right in the end check the fuel wires would interfere Lead to engine speed becomes higher 3...

Page 56: ...oil level MIN Out of range add or reduce the amount of oil Adjustment Open brake master cylinder cover add brake fluid to the standard oil NOTE 1 Brake fluid is corrosive if the brake oil cup or body...

Page 57: ...tire burstor damage caused by a vehicle accident The total weight does not include the Knight passenger accessories and cargo 2 Check Tread tire wall replacement tire wear cracks Tread depth Minimum...

Page 58: ...nal imbalances degrade performance 3 In order to give full play to the battery performance battery before use the battery implementation of the initial charge 4 New battery added to the electrolyte al...

Page 59: ...dance with the demolition order reverse 3 19 Fuse check Note Removable fuse the main switch cut to the OFF position Check Tools multimeter Way red probe then fuse either end black Probe connected to t...

Page 60: ...f gasoline is normal color 3 Check the escape of gasoline is bubble free 1 dismantle the under cover 2 find the drain valve 3 turn on the key 4 press the drain valve fuel drained air bleed 5 repeat 3...

Page 61: ...nance the implementation of simple checks short road test check the clutch without severe wobble or abnormal sound Roller without serious wear V belt is aging cracking 3 the close end face to left 4 i...

Page 62: ...y c Test results 1 If more than the maximum value Make sure the combustion chamber whether carbon deposition 2 if less than the minimum value Please add a few drops of oil to the cylinder in the spark...

Page 63: ...I R I I Clutch shoes 4T Check or replace it if necessary I I I I I Tires 4T Worn out check or replace it if necessary I I I I Wheel bearing 4T Fasten tightly if loosen I I I I I I Front fork 4T Leaki...

Page 64: ...Change the brake fluid hose every four years Exhaust control system only be valid for the bike equipped catalyst Catalyster will not be possible to be withdrawn individual the only you have to do is...

Page 65: ...Fuel injection systems 4 4 1 Second generation injection system Feature of 2nd stage EMS feature 1 small light 2 integrity 3 accuracy 4 simple EMS structure A EMS structure B 65...

Page 66: ...ection systems 4 4 2 Electronic injection system introduced 4 2 1 ECU electric control unit Location Important PIN no of ECU Fault phenomenon EMS lights lit vehicle can not start 1 PIN 18 PIN 19 PIN 3...

Page 67: ...ult phenomenon 1 vehicle can not start 2 The spark plug no ignition with the fuel injector fuel injection EMS light is on six long and six short Crank angle perception circuit is broken or open circui...

Page 68: ...emperature to determine the hot and cold car conditions the fuel injection quantity and ignition timing Correction compensation Principle the use of high and low temperature resulting in a change in r...

Page 69: ...or so throttle unresponsive EMS light is on 0 length short throttle opening degree sensor failure maintenance Preliminary Gauge connected 1 overhaul the initial impression why the first check the fail...

Page 70: ...r pressure ECU judge intake or compress stroke to decide injection ignition theory different pressure outputs diferent resistance intake pressure sensor measurement fault phenomenon Idle speed will be...

Page 71: ...njection systems 4 4 2 6 Injector Location Injector principle function inject the gas mixed with air theory control the opening time interval to decide the gas amount Injector measurement Impedance 12...

Page 72: ...three long 3 short injector circuit open or break overhaul of the initial impression method and connected initial impression method The first to confirm the fuel pump with or without oil the nozzle ca...

Page 73: ...3kgf cm2 Principle pressure adjustment allows gas pressure to maintain stability The fuel pump measurement Nozzle internal line or external line break or open circuit photo into a spray The nozzle doe...

Page 74: ...Location Fall down sensor Function vehicles and dumping more than 65 degrees for any reason you can cut off the power turn off Principle the use of gravity to make the ball move position touch sensor...

Page 75: ...control the amount of bypass air volume in order to control and maintain the engine idle speed ISC control method Instance When the engine is cold it may be due to idle too low and turn off the ECU w...

Page 76: ...used scooter occur 1 Hard to start the engine 2 Engine Idle speed is unstable 3 Other unstable situation To initialize the ISC then the ISC reset to control zero point program Normal idle settings 15...

Page 77: ...Fuel injection systems 4 4 3 EMS system Repairing tool pocket tester wiring part no S905310005 Use spark gauge Injector test line group S905310005 connect minimum distance 6mm Plug cap ground 77...

Page 78: ...e relay Frequency of injection recommend the use of LED Direction light relay fuel pressure gauge part no S905330008 measure the fuel pressure standard 3kgf cm2 usage 1 dismantle the hose to injector...

Page 79: ...S320840G01 name quick diagnostic How to use quick diagnostic 1 Prepare quick diagnostic 2 Open the rubber cover inside the luggage comp 3 Plug in the quick diagnostic 4 turn on the key 5 wait for abo...

Page 80: ...Fuel injection systems 4 name connect cable Quick diagnostic table 80...

Page 81: ...defect code memory 1 plug quick diagnostic into vehicle seat 2 wide open the throttle turn on the key 3 after the EMS led off release the throttle 4 don t turn off the key until EMS led on again 5 tu...

Page 82: ...tial gear 5 5 1 Disassembly of the engine assembly Removing the steps Back luggage 1 Remove the screws 2 take out the Back luggage Muffler 1 Remove the nut screw washer 26 28 29 30 take out the Muffle...

Page 83: ...ear 5 Rear brake calipers 1 Remove the screw 19 23 take out the rear brake calipers and brake hose clamp Remove the air cleaner 1 Remove the EEC TUBE and PCV TUBE 2 Turn loose clip 3 Remove the air cl...

Page 84: ...nsor Starter motor A C G Starter motor lion wiring terminals Throttle assembly Remove the throttle assembly screws 2 Oil cooler hose pipe 1 Remove the screw 14 take out the Oil cooler hose pipe 1 and...

Page 85: ...the engine hanger 1 fixed nut 2 Remove the engine hanger 1 mounting bolts Separation of the engine and the frame Remove the reverse differential gear Steps please refer to the reverse differential gea...

Page 86: ...ove the flat washer nut 7 8 9 take out the Rear Swingarm 6 3 Remove the screw 3 take out the Engine lower hanger 2 Center stand 1 Remove the screw 13 take out the SLIDE BUSH 11 SPRING 15 RUBBER DAMPIN...

Page 87: ...rential gear 5 5 2 Engine disassembly 5 2 1 Cylinder head disassembly 1 Remove the screw 10 11 take out the fan cover 8 Torque values 10 11 0 9 1 1kg m 2 Remove the cooling cowl 1 2 4 screws Torque va...

Page 88: ...r models Remove the bolts 5 8 removing the tube comp 7 washers 9 and the cooling cowl 1 4 Remove the cylinder head cover 4 screws A Remove the fixing screws 4 take out the separator 3 B Check the cyli...

Page 89: ...Remove the inner chain adjuster 2 and washers 4 6 Remove the screws 10 6 1 Remove the screws 12 camshaft LOCK PIN camshaft holder Torque values Parts 3 0 9 1 1kg m Parts4 0 9kg m 6 2 Remove the camsha...

Page 90: ...Remove the cotter valve Relax the valve removal tool The order to remove the valve spring retainer valve spring flain washer seals valve use valve oil seals needle nose pliers folder Cylinder head ins...

Page 91: ...clockwise rotation of the flywheel to the flywheel of the T markon the The prospective the crankcase on the instructions ribs 2 Confirm the large hole on the camshaft at the same time appear in the v...

Page 92: ...d washers 5 3 Using needle nose pliers to remove C type retaining ring 3 4 Remove the piston pin 8 the piston 2 and the positioning pin 4 Piston rings demolition Use the left and right hand thumb pist...

Page 93: ...ard 1 Install the oil scraper ring spacer ring ring 3 and 4 of the ring 2 Side upward install piston rings 2 iron gray 3 Side upward install the piston ring 1 Metallic Silver 4 Piston ring can rotate...

Page 94: ...nicked Cylinder installation steps Installed in accordance with the removal procedure in reverse Installation Notes 1 Before installation cylinder surfaces piston rings painted oil 2 piston rings can...

Page 95: ...Remove the CVT parts Remove the nut 16 sequentially removed A driven face 17 B face movable drive 10 and Boss drive face 11 C clutch outer body 14 D driven pulley 12 E V type belt 13 CVT installation...

Page 96: ...the the face movable drive trench right side To Weight roller life and prevent face movable drive of abnormal wear Install the slide piece to the pamp plate pressed into the triangle facing upwards 3...

Page 97: ...ion 1 Remove the screws 1 take out the fan 3 1 Remove the screws 1 take out the flywheel 3 electric plate puller to remove the flywheel 3 Remove the fixed screws 1 3 take out the stator 4 Torque M5 0...

Page 98: ...C Using a one way clutch nut removal tool remove the lock nut 9 and washers 8 takeout the one way clutch D Remove the lock pins 12 A Remove the oil filter cover 6 17mm B Remove the oil strainer 3 spri...

Page 99: ...take out the sprkt oil pump drive 1 and oil pump drive chain 2 7 A Remove the bolts 17 take out the oil pump 16 B Remove the screws 13 15 take out the right crankcase 14 When installing oil pump oil p...

Page 100: ...ine Reverse differential gear 5 8 Remove the right crankcase cover Remove the Crankcase gasket 13 crankshaft 11 chain camshaft 10 lock pin 12 Oil pump above the arrow mark toward the crank shaft hole...

Page 101: ...tortion 3 Weight roller worn out 4 Driving plate dirty Note No grease and oil should be distributed over driving belt and driving plate B Measurement data Hooligan 170i Item Standard value mm Limit of...

Page 102: ...ush of slide driving plate 2 Remove screw and disassemble the cover of slide driving Plate 3 Remove ramp plate 4 Remove weight roller 3 Checlomg 1 Check the wearing condition of weight roller limit of...

Page 103: ...ter limit of use change it above 33 95mm e Check wearing condition of slide driven plate and measure its Inner diameter limit of use change it above 34 00mm f Check is there any wearing occur to the d...

Page 104: ...ent of valve clearance Poor adjustment of valve clearance Valve being burned out or bent Valve burned or damaged spring Valve timing is not correct Camshaft is worn out Valve spring is damaged Chain a...

Page 105: ...and Valve guide IN 0 010 0 037 0 08 EX 0 030 0 057 0 10 Check cam shaft Check the convex surface and the height and see whether it has been damaged Check camshaft If the bearing is loosen or worn out...

Page 106: ...e cam shaft on the cylinder head C Install the cam chain onto the cam shaft gear D Install the locking pin E Install the camshaft holder washer and nuts on the cylinder head 6 Lock tightly the cylinde...

Page 107: ...stall the oil pump cover 5 Put on the screws and tighten them 6 After installing turn the shaft lightly to assure installation 7 Place the oil pump into the carnkcase Note The notch of the oil pump sh...

Page 108: ...l b Blockage in oil route c Piston loop seizes or improperly install ation c Did not use the fuel oil recommended d Worn out of valve s oil seal Measurement data Hooligan 170i item Standard Value mm L...

Page 109: ...Engine Reverse differential gear 5 5 3 4 Cylinder and piston A Trouble shooting B The Operation notice C Data D Dismaniling cylinder piston E Installing cylinder piston 109...

Page 110: ...contact surface of gasket must be clean 3 Dismantle cylinder and cylinder head by screw driver Do not injure the contact surface 4 Cylinder inner surface and piston outer face can t be injured Contact...

Page 111: ...cylinder Vertical to piston pin and in X Y direction to measure cylinder bore from the upper middle and lower location 4 The maximum clearance between the cylinder and piston pin 5 The difference bet...

Page 112: ...ferential gear 5 c Checking the flatness of cylinder contact surface d Connecting rod small end inner diameter measurement Limit of use change it when above 0 05mm Limit of use change a new one when a...

Page 113: ...ssembly the piston piston pin and piston pin clip b Installing piston 1 Fix the lock pin and gasket on the crankcase 2 Lubricate the Cylinder inner surface piston and piston rings by Motor Oil 3 Insta...

Page 114: ...d value mm Limit of use mm Clearance of connecting rod big end axle direction 0 10 0 35 0 55 Clearance of connecting rod big end vertical direction 0 006 0 014 0 04 Swingness of the crank shaft journa...

Page 115: ...Engine Reverse differential gear 5 1 Check the looseness of crankshaft bearing If it is loosen replace to a new one 115...

Page 116: ...hanism A Troubleshooting Engine can be started but the vehicle doesn t move 1 Gear worn out or cracked 2 Gear burnt out Noise occur when running 1 Gear worn out burnt or gear surface 2 Bearing worn ou...

Page 117: ...box cover 5 Remove the final reduction gear 9 axle drive 8 idle gear 10 and driving shaft 6 6 Clean up the gear box Locking torque M8 P1 25 40L 2 0 3 0kg m Locking torque Parts4 M8 P1 25 50L 2 5 2 8k...

Page 118: ...eck the wearing condition of idle gear shaft and idle gears 3 Check the wearing condition of the final reduction gear 4 Check the wearing condition of the oil seal and bearing D Assemble the final tra...

Page 119: ...wheel measure Steps 1 Remove the 5 front brake bolts 2 2 Remove the front axle nut 6 3 Remove the 5 front axle 4 spacer ring 3 code table gear and 2 wheels Torque Parts5 5 0 6 0kg m Measuring Horizon...

Page 120: ...f the bearing removal tool will hammer out the single sealed ball bearings Check 1 Bearing Rotating ring true and different sound Replace the ball bearings 2 Oil seal Specification 22 35 7 Wear damage...

Page 121: ...Front wheel Front axle Measurement 1 Thickness Standard values 3 6mm Use limits 3 1mm Beyond the limits replace 2 lost roundness 0 3mm Beyond the limits replace Check Speed meter gear 1 Pinion speed...

Page 122: ...Handle bar 2 Remove the Front wheel 3 Remove the front fender 4 Remove the screws with washers 15 take out the clip 14 5 Using the front fork disassembly tool Remove the steering shaft lock nut 5 and...

Page 123: ...ation will cause handle tube rotating flow and body shaking unstable Tools Fork bearing disassembly tool Demolition The use of impact rod will upper bearing cage and lower bearing cage Qiaoxia Install...

Page 124: ...ont damper can be installed in accordance with demolition reverse See the chapter 6 2 Step The hand will upper ring shape nut locking Using fork disassembly tool to the Leftward and then tighten about...

Page 125: ...e left and right damper bolts 1 Installation Front damper can be installed in accordance with demolition reverse NOTE The front damper has a different sound or too soft replace the entire set of dampe...

Page 126: ...ve the yoke spring and brake pad Disassembly Step 1 Remove the screws of the brake calipers 2 2 will push the piston back 3 Remove the screw 4 Remove the yoke springs and brake pads Measurement brake...

Page 127: ...Removing the rear wheel 1 Remove the nut screw washer 26 28 29 30 take out the muffler 31 and packing 25 2 Remove the screw 19 23 take out the rear brake calipers and brake hose clamp 3 Remove the lef...

Page 128: ...system wheel 6 4 1Use the slotted screwdriver remove the Rubber 10 4 2 Remove the flat washer nut 7 8 9 take out the Rear Swingarm 6 4 3Remove the screw 3 take out the Engine lower hanger 2 4 4 Remove...

Page 129: ...let the oil cup is taking the time to suck Into the air 5 Tighten the drain screw and brake master cylinder cover The following strut several times to check the brake lever clearance whether Normal i...

Page 130: ...t location 1 FLASHER RELAY ASSY 10 2 HORN 11 3 IGNITION MAIN SWITCH 12 4 TOPPLE SWITCH 13 1 FUEL PUMP 11 1 RELAY 16 2 STARTER RELAY 17 3 IGNITION COIL 18 4 REGULATE RECTIFIER 20 20 1 ECU 3 1 DIAGNOSE...

Page 131: ...Denso unit 7 Locate the position of the main wiring 131...

Page 132: ...start relay f one way clutch Check the process Project Handle 1 Battery check the voltage 12V Please replace or recharge 2 Fuse check 15A KEY the ON Replace 3 Main switch KEY ON Check the line color R...

Page 133: ...en circuit B W or start switch is bad 6 Starter motor check t Use battery test motor Dysfunction to be replaced 7 One way clutch Repeat check a Fuse b Battery Check the one way clutch ball is bad spri...

Page 134: ...r probe stalls Judgment switch O conduction normal LB replace Check start the motor actuator is normal Tools 12V battery Method directly across the 12V voltage to the motor Not rotate rotate too slowl...

Page 135: ...multimeter Measurement Voltage at20 when 12 8V or more Insufficient voltage recharged or replaced Measurement the A C G connect a voltmeter hook table or pointer Tools multimeter Control voltage 14 2...

Page 136: ...age current testing Tools ammeter A 1 Method Turn off the main switch 2 Negative battery removed Connect ammeter probe connection wire harness battery negative line Probe connected to the battery Test...

Page 137: ...t light Replace Measurement Method check for all lamps Note 1 The bulbs just remove the very high temperatures are not directly handling them 2 The bulbs surface is not contaminated with oil or touch...

Page 138: ...ange 12V Red White 12V 0V Replace the main switch or lines open circuit 4 Headlight relay Orange 12V yellow ECU black 12V Gray out 12V The orange 0V open circuit Yellow ECU control source ECU or lines...

Page 139: ...Denso unit 7 Blue brown white 0V check line is open circuit black line with frame is not turned on lines open Repeat check circuit 139...

Page 140: ...d White 12V 0V Replace the main switch or lines open circuit 4 Flasher relay checking line color light blue 12V Blue White out 12V black Light Blue 0V lines open circuit Blue White 0V replacement Flas...

Page 141: ...ignal voltage is connected to the ECU ECU without receiving this voltage or voltage at the same time the vehicle will not start Horn Tool Battery multimeter Check line Items Line color Probe Stalls Me...

Page 142: ...current to control big current Usage fuel pump injector EMS whole system headlamp Relay measurement DC 12V use the pocket tester 1 find the control coil 2 fit 12V to the control coil 3 the relay soun...

Page 143: ...change specifications and who frequently replace the fuse check whether the line short circuit in order to ensure road safety dismantle 1 luggage comp 2 battery cover at the right of battery FUSE 1A 5...

Page 144: ...i ME Xhot such as the fuse burned failure phenomenon Unable to launch fuel pump actuator whether the apparent fault codes 3 7 short and 4 long 5 short transistor ignition coil failure oxygen sensor c...

Page 145: ...Denso unit 7 7 9 Injection system wiring diagram Line color injection system 1 gray Ground 2 pink ECU provides 5V voltage 3 red white the battery voltage 4 Orange main switch KEY ON 145...

Page 146: ...there 12V 7 Check the fuel pump relay Red White line Are Fuse 5A there 12V 7 1 Check the fuel pump relay dark green line wire open circuit or ECU is bad ECU relay wire whether the conductive with the...

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